Note: Descriptions are shown in the official language in which they were submitted.
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DUMP BODY
PRIORITY CLAIM AND CROSS-REFERENCE
TO RELATED APPLICATION
[0001] This
application claims the benefit under 35 U.S.C. 119(e)(1) of U.S.
Provisional Application No. 62/413,733, filed October 28, 2016, which is
hereby
incorporated by reference in its entirety.
BACKGROUND
[0002] Dump
trucks and like vehicles are widely used in the mining industry, as well as
other industries, for moving large quantities of materials from location to
location.
Generally, a dump truck includes a dump body configured to hold the materials
to be moved,
pivotally mounted to a truck chassis. The dump body is pivotally attached to
the chassis (or
frame) of the truck so that the dump body can be loaded while in a first
position relative to
the truck chassis and so that it can be oriented into a second position for
unloading.
[0003] When the
dump body is in the first position relative to the chassis of the truck
(e.g., a rest position), the dump body may be loaded or filled as desired. For
instance, the
dump body may be filled with rocks, raw minerals, dirt, and the like, to be
transported away
from a work site (such as a mining dig site, for instance) or to a processing
site, a fill site, etc.
To unload the dump body, the dump body is moved into the second position
(e.g., an
extended or tilted position). While in the extended position, materials within
the dump body
are spilled out of an opening at the lowest point (e.g., the back end) of the
dump body.
[0004]
Accordingly, a dump body is generally manufactured of materials that are
harder than the materials to be hauled within the dump body. This reduces wear
on the dump
body, and particularly at locations of the dump body where the hauled
materials move against
the surface of the dump body. It is also desirable that the dump body be
formed or
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manufactured to be strong, to be capable of enduring many heavy loads without
material or
manufacturing failures. However, it is also desirable that the dump body be as
light as
practical for the desired volume of the dump body, to optimize the amount of
material that
can be transported with each load (since the weight of the dump body adds to
the gross
weight of the loaded vehicle, and the vehicle has a maximum gross weight
capability) as well
as to minimize the amount of fuel that is used to transport each load.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The
detailed description is set forth with reference to the accompanying figures.
In the figures, the left-most digit(s) of a reference number identifies the
figure in which the
reference number first appears. The use of the same reference numbers in
different figures
indicates similar or identical items.
[0006] For this
discussion, the devices and systems illustrated in the figures are shown
as having a multiplicity of components. Various implementations of devices
and/or systems,
as described herein, may include fewer components and remain within the scope
of the
disclosure. Alternately, other implementations of devices and/or systems may
include
additional components, or various combinations of the described components,
and remain
within the scope of the disclosure. Shapes and/or dimensions shown in the
illustrations of the
figures are for example, and other shapes and or dimensions may be used and
remain within
the scope of the disclosure, unless specified otherwise.
[0007] FIG. 1
shows an example dump truck, as an example application environment
for an example dump body as disclosed herein.
[0008] FIG. 2
shows a front perspective view of an example dump body, according to
an implementation.
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[0009] FIG. 3
shows a back perspective view of an example dump body, according to
an implementation.
[0010] FIG. 4
shows a top perspective view of an example dump body, according to an
implementation.
[0011] FIG. 5
shows a bottom perspective view of an example dump body, according to
an implementation.
[0012] FIG. 6
shows a side view of an example dump body, according to an
implementation.
[0013] FIG. 7
shows a top view of an example dump body, according to an
implementation.
[0014] FIG. 8
shows a front view of an example dump body, according to an
implementation.
[0015] FIG. 9
shows a bottom view of an example dump body, according to an
implementation.
[0016] FIG. 10
shows a back view of an example dump body, according to an
implementation.
[0017] FIG. 11
shows a detail view of example weld seams of an example dump body,
according to an implementation.
[0018] FIG. 12
is a flow diagram illustrating an example dump body manufacturing
process, according to an implementation.
DETAILED DESCRIPTION
Overview
[0019]
Representative implementations of devices and techniques provide a dump body
(e.g., dump bed, dump tray, etc.) for a dump truck, for example. An example
dump truck
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100, having an example dump body 102, is shown in FIG. 1. The illustration of
FIG. 1 is not
intended to be limiting, however. The dump truck 100 and the dump body 102 may
be of
various sizes, and may have various dimensions and configurations, and include
various
accessories.
[0020] For
example, in various implementations, the dump body 102 is custom
engineered (e.g., in size, dimensions, capacity, construction materials,
attachment points, etc.)
for a desired application, including being custom fit for a particular truck
100, or for a range
of trucks 100. In a range of applications, a dump body 102 may be designed for
carrying 40
tons to 400 tons of material (corresponding to a gross vehicle weight of about
157,000 lbs. to
1,375,000 lbs., respectively, on haul trucks having a corresponding chassis
weight of about
70,000 lbs. to 600,000 lbs., respectively). In other applications, a dump body
102 may be
designed for lesser or greater load-carrying capacity.
[0021] The dump
body 102 is pivotally attached to the chassis (or frame) of the truck
100. When the dump body 102 is in a first position (e.g., a rest position, as
shown in FIG. 1)
relative to the chassis of the truck 100, the dump body 102 may be loaded or
filled as desired.
For instance, the dump body 102 may be filled with rocks, raw minerals, dirt,
and the like, to
be transported away from a work site (such as a mining dig site, for instance)
or to a
processing site, a fill site, etc.
[0022] To
unload the dump body 102, the dump body 102 is moved into a second
position (e.g., an extended or tilted position). While in the extended
position, materials
within the dump body 102 are spilled out of an opening at the lowest point
(e.g., the back
end) of the dump body 102.
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Example Dump Body
[0023] As shown
in FIGS. 2 - 10, a dump body 102 may include a shell 202 and a
canopy 204. For example, the shell 202 includes the portion of the dump body
102 that is
intended to be filled and/or to carry a load. As shown in FIGS. 2 ¨ 10, in
various
implementations, the dump body 102 includes a curved or semi-elliptical shaped
shell 202.
The front head 206 forms the front portion of the shell 202, and it may be
planar or curved
overall. As shown in FIG. 2, the perimeter of the front head 206 illustrates
the curved or
semi-elliptical shape of the shell 202. The canopy 204 includes the portion of
the dump body
102 ahead of the shell 202 that covers and protects the cab of the truck 100.
In alternate
embodiments, the canopy 204 may not extend over the cab of the truck 100, or
may not be
present on the dump body 102.
[0024] The
novel curved or semi-elliptical shape of the shell 202 provides maximum
strength with reduced overall weight (as compared to traditional rectangular-
shaped dump
body shells), to maximize load-carrying capacity, which improves efficiency.
For instance, a
dump body 102 with a curved or semi-elliptical shaped shell 202 is capable of
carrying
significantly more load than a similarly weighted traditional rectangular-
shaped dump body
shell.
[0025]
Referring to FIGS. 2 ¨ 6, 9, and 10, in various embodiments, the dump body 102
also includes one or more bolsters 208 to provide strength and stability to
the shell 202, and
one or more gussets 210 to support the canopy 204 relative to the shell 202.
In alternate
implementations, no bolsters 208 and/or no gussets 210 may be used with the
shell 202. For
instance, the shell 202 may have sufficient strength (due to the size,
construction, materials,
etc. of the shell 202) without the bolsters 208 and/or gussets 210.
[0026] As shown
in FIGS. 2 ¨ 10, in various embodiments, the dump body 102 is
comprised of multiple curved (contoured, bent, radiused, rolled, etc.) body
panels 212, which
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are welded together, for example, to form the curved or semi-elliptical shaped
shell 202. In
some embodiments, the dump body 102 also includes multiple flat (planar) body
panels 212,
as shown. In various implementations, the panels 212 may be comprised of
aluminum, mild
steel, alloy steel, tool steel, or other metallic plate and the like.
[0027] The body
panels 212 are welded with overlapping seams 302, as illustrated in
FIGS. 3, 4, 7, and 11, which form laminated seams 302 for increased structural
support. The
overlapping seams 302 allow for a reduced number of external structural
supports (e.g.,
bolsters 208, etc.), which reduces the weight of the dump body 102 without
compromising
strength or capacity of the dump body 102. In various embodiments, the panel
212 overlap,
and resulting laminated seams 302 can have a width of between 2 and 30
centimeters. In
alternate embodiments, the overlap and resulting seams 302 can have a width
that is less than
2cm or greater than 30cm.
[0028] As shown
in FIGS. 3, 4, and 7, the overlap of the body panels 212 follows a
front-to-rear "step-down" overlap arrangement, where a leading edge of each
successive
panel 212 is attached to the underside trailing edge of the previous
(preceding) panel 212
(when looking from the inside surface of the dump body 102, see top view of
FIG. 7 for
example). This results in an approximately 1 degree flare from the front to
the rear of the
shell 202. The "step-down" overlap arrangement allows for quick and full
material release
when unloading the shell 202. Additionally, the "step-down" overlapping design
causes the
load materials to flow over, rather than across the welds at the seams 302
joining the panels
212 during unloading of the shell 202.
[0029] Thus,
the "step-down" overlap design protects the weld seams 302 along the
edges of the panels 212 from damage or wear due to the material flow out of
the shell 202.
For instance, much of the materials flowing out of the shell 202 during
unloading does not
directly impact the welds, which can be comprised of a softer material than
the body panels
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212. Rather, the material flow is directed over the welds by the "step-down"
overlap
arrangement.
[0030] In
various implementations, the overlapping panels 212 are welded at the
overlapping seams 302, where the edges of the panels 212 overlap. Additionally
or
alternately, as shown in FIGS. 3, 4, 7, and 11, plug welds 304 may be used to
weld the
overlapping seams 302. A plug weld 304 includes an opening 306 through a first
layer (e.g.,
the upper layer) of the overlapping seam 302 of panels 212 that exposes a
second layer (e.g.,
the lower layer) of the overlapping seam 302 through the opening 306. The
first layer panel
212 of the overlapping seam 302 is welded to the second layer panel 212 within
the opening
306, at the periphery of the opening 306. In various implementations, the plug
welds 304
may be made on the inside of the dump body 102, as shown in FIGS. 3 and 4 for
example, on
the outside of the dump body 102, or a combination of on the inside and on the
outside of the
dump body 102, if desired.
[0031] In
various implementations, the plug welds 304 are located along the seams 302
at predetermined points for strength and for optimized wear. For example, a
weld around the
opening 306 (i.e., at the periphery) of the plug weld 304 provides
approximately three times
the weld length (and an associated strength) of a standard beveled welded
joint. Additionally,
the weld bead of a plug weld 304 is generally protected against wear and
damage, since it is
located within the "pocket" of the opening 306.
[0032] As also
shown at FIG. 11, in an implementation, one or more of the edges of
some or all of the body panels 212 of the dump body 102 are "formed" (e.g.,
serrated,
notched, toothed, scalloped, indented, curved, patterned, embellished, or
otherwise fashioned
with regular or irregular patterns), to have other than a generally straight
edge (one example
is shown at 308). Overlapping one or more body panels 212 with "formed" edges
creates an
overlapped "formed" seam 310, and welding along the "formed" edge of the
"formed" seam
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310 creates a "formed" weld 312. In various implementations, the "formed"
welds 312 are
located along the "formed" seams 310 at predetermined points for strength and
for optimized
wear. For example, a "formed" weld 312 along a "formed" edge can also provide
additional
weld length (and an associated strength) as compared to a generally straight,
standard beveled
welded joint. Additionally, at least portions of the weld bead of a "formed"
weld 312 may be
protected against wear and damage, based on the pattern of the "formed" weld
312 relative to
the general flow of material out of the shell 202 when the dump body 102 is
emptied.
[0033] In
embodiments where multiple types of welds (i.e., edge welds, plug welds,
and/or "formed" welds, or other types of welds) are used, one weld type
reinforces the other
weld type, with the combination resulting in a much stronger shell 202 for its
weight.
[0034] In some
embodiments, additional plug welds 304 (or "formed" welds 312) may
be used to reduce or eliminate the delamination process of the shell 202.
Delamination
includes the separation of the panels 212 at the seams 302. The additional
plug welds 304
and/or "formed" welds 312 strengthen the seams 302 against delamination.
[0035] In some
embodiments, portions of the shell 202 may be lined, e.g., with harder,
more wear resistant materials, etc. For example, one or more liner portions
(not shown) may
be placed within the shell 202 per user specifications, or the like.
[0036] In
various implementations, the dump body 102 may be comprised of multiple
modular portions (not shown), intended to be assembled at a designated site
location.
Delivery of the dump body 102 is facilitated when it is transported in smaller
sections. For
example, the dump body 102 may be manufactured in 2 or more modular portions,
including
dozens or more modular portions, with key assembly components (such as sub-
frame and rear
pin bosses, for example) pre-mounted on the modular portions before delivery.
The dump
body 102 can be easily assembled on site, based on the modular components.
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[0037] The
modularity of the dump body 102 is enhanced by the use of the multiple
body panels 212. For instance, modular portions can be formed at the natural
edges of some
of the body panels 212, where seams 302 are to be formed. Additionally, the
modular design
of the dump body 102, using the panels 212, can allow for a staged build of
the dump body
102 and can reduce manufacturing time. For instance, manufacturing time can be
reduced
due to the novel joint design (using the overlapping seams 302) and the
welding techniques
(applying edge welds at the overlap seams 302, at the plug welds 304, and/or
the "formed"
welds 312).
[0038] Although
various implementations and examples are discussed herein, further
implementations and examples may be possible by combining the features and
elements of
individual implementations and examples.
Representative Process
[0039] FIG. 12
illustrates a representative process 1200 for implementing techniques
and/or devices relative to forming a dump body arranged to hold a payload
(such as dump
body 102, for example). The process 1200 includes forming a plurality of
contoured panels
(such as body panels 212, for example) together to form the dump body. The
example
process 1200 is described with reference to FIGS. 1 ¨ 12.
[0040] The
order in which the process is described is not intended to be construed as a
limitation, and any number of the described process blocks can be combined in
any order to
implement the process, or alternate processes. Additionally, individual blocks
may be
deleted from the process without departing from the spirit and scope of the
subject matter
described herein. Furthermore, the process can be implemented in any suitable
hardware,
software, firmware, or a combination thereof, without departing from the scope
of the subject
matter described herein.
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[0041] At block
1202, the process includes forming a shell portion having a curved or
semi-elliptical shape. The forming includes the remaining steps:
[0042] At block
1204, the process includes overlapping a plurality of contoured body
panels.
[0043] At block
1206, the process includes forming a plurality of laminated seams at
overlapped portions of the body panels with the overlapping.
[0044] At block
1208, the process includes welding adjacent overlapping body panels
at the laminated seams to join the adjacent overlapping body panels.
[0045] In an
implementation, the process includes forming a plurality of openings
through an upper layer of each of the plurality of laminated seams that
exposes a lower layer
of each of the plurality of laminated seams, and welding around a periphery of
each of the
openings to join the lower layer of each of the plurality of laminated seams
to the upper layer
of each of the plurality of laminated seams. In an embodiment, the process
includes welding
inside each of the openings to form the plug welds within the openings.
[0046] In an
implementation, the process includes protecting weld beads of the plug
welds against wear and damage by locating the weld beads fully within the
openings. This
allows materials exiting the dump body to flow over the plug welds, rather
than directly
impacting the welds. Additionally, the process can include reducing or
eliminating
delamination of the body panels by forming the plug welds within the openings.
[0047] In
another implementation, the process includes welding along edges of the
plurality of body panels at the plurality of laminated seams to join adjacent
and overlapping
body panels at the plurality of laminated seams. In some embodiments, the
process includes
welding along "formed" edges of the body panels, where the edges have been
"formed" (e.g.,
serrated, notched, toothed, scalloped, indented, curved, patterned,
embellished, or otherwise
fashioned with regular or irregular patterns), to have other than a generally
straight edge. In
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the embodiments, the process can include protecting at least portions of the
weld bead of the
"formed" welds against wear and damage, based on the pattern of the "formed"
weld relative
to the general flow of material when the dump body is emptied. In various
embodiments, the
process can include using plug welds, seam welds, "formed" welds, or a
combination of plug
welds, "formed" welds, and/or seam welds to join the body panels. In alternate
embodiments, other additional or alternate welding techniques may be employed.
[0048] In an
additional implementation, the process includes lining an inside surface of
the shell portion with a wear-resistant material that is harder than a
material of the shell
portion. This protects the softer material of the dump body, and allows for
greater longevity.
[0049] In a
further implementation, the process includes assembling the dump body
from two or more modular portions, where each modular portion comprises a
plurality of
body panels. Forming the modular portions along the natural edges of the body
panels can
improve assembly times and manufacturing efficiency.
[0050] In
alternate implementations, other techniques may be included in the process in
various combinations, and remain within the scope of the disclosure.
Conclusion
[0051] Although
the implementations of the disclosure have been described in language
specific to structural features and/or methodological acts, it is to be
understood that the
implementations are not necessarily limited to the specific features or acts
described. Rather,
the specific features and acts are disclosed as representative forms of
implementing the
claims. Further, individual features of various embodiments may be combined to
form other
embodiments not specifically described.
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